Formation of mullite from ground product of a kaolinite-aluminum trihydroxide mixture by solid phase reaction

The present paper describes the effect of grinding a kaolinite/aiuminum-trihydroxide mixture using a planetary ball mill on the structure of the ground product and the mean thermal expansion coefficients of samples sintered from the unground and ground mixtures. The size reduction of the mixture predominates in the early stage of grinding and the obtained fine particles aggregate subsequently with an increase in grinding time. The crystal structure of the mixture is collapsed easily into a disordered one, of which amount increases with an increase in grinding time. Only mullite phase was detected in the sintered body of the ground products at relatively lower temperature 1523K except for anatase as an inherent impurity, whereas corundum, cristobalite and Al-Si spinel phases besides mullite were formed in the sintered body of the unground mixture. The thermal expansion coefficients of sintered bodies of the 120 minutes-ground mixture are considerably lower than those of the unground mixture by about 10%. Consequently, the planetary milling enables us to improve the uniform mixing state at the atomic scale resulting in direct formation of mullite with high purity at relatively low temperature with a lower thermal expansion coefficient of the sintered body.